JPH10633A - Molding method of heat insulating sandwich panel for building materials - Google Patents

Abstract

(57) [Summary] [Problem] In molding a heat insulating sandwich panel for building materials, air remaining between the upper surface material and the upper surface heating / pressing platen which is one of the causes of the thickness defect of the panel is removed. Provided is a molding method having an exhaust means for discharging and removing. SOLUTION: In integrally molding a heat insulating sandwich panel for a building material, when a raw material is not injected into a molding space, an upper surface material is bent by its own weight, and the residual air is generated. For the purpose of removing residual air, slit rows or pinhole rows are formed at the four corners of the upper surface material of the molding space. Residual air is discharged to the molding space via the slit row or the pinhole row, and the residual air leaking into the molding space is discharged to the outside through an exhaust hole provided in the frame material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement in a method for forming a heat insulating sandwich panel for a building material such as a 2.times.4 type in which a rigid polyurethane foam, a frame material and a soft surface material are integrated.

[0002]

2. Description of the Related Art In the housing field, in order to provide high airtightness and high heat insulation, and to shorten the construction period, roof materials, floor materials,
As a wall material or the like, a sandwich panel in which a surface material such as a rigid polyurethane foam, a frame material, and soft paper is integrally molded is used as a building material.

[0003] In order to integrally mold a rigid polyurethane foam using a raw material of rigid polyurethane and both surface materials, both surface materials and a frame material are previously placed between a heating and pressure platen heated to a predetermined temperature. Set, mix the hard polyurethane stock solution with a high-pressure or low-pressure urethane foaming machine, inject it into the molding space formed by both surface materials and the frame material, foam and harden. It is a general construction method to mold.

[0004] The surface material of a molded panel made of a soft material bends when it is set between the upper and lower heating and pressure platens.
An air accumulation space (hereinafter, referred to as a local space) is generated between the upper surface heating and pressure platen. With local space present,
When the rigid polyurethane stock solution is injected and foamed, the foam first expands in the direction of the frame material by pressing the vicinity of the center of the upper surface material against the upper surface heating / pressure platen as the foam expands. According to this, the air in the molding space is exhausted from the exhaust hole provided in advance, and the air in the local space escapes along the heating / pressure platen at the beginning. Since the surface material is pressure-bonded to the upper and lower heating and pressure platens around the formwork, the foam will eventually reach the thickness of the frame between the upper and lower heating and pressure platens. That is, when filling the molding space,
There is a problem that the air in the local space does not have a sufficient escape space, and often remains as a dent on the panel surface, resulting in poor appearance.

Several methods have been proposed and implemented as a method for discharging air remaining in the local space. That is, 1) The thickness of the frame material of the molded panel is 0.5 to 1 from the regular size.
mm and set the top surface material. Then
A liner having a regular thickness is arranged on the outside of the frame material for increasing the thickness, and is closely attached to the upper surface heating / pressure platen. Therefore, a gap of 0.5 to 1 mm is generated between the surface material set on the frame material and the upper surface heating / pressing platen in close contact with the liner, and the trapped air flows out of the gap. 2) On the frame material of the molded panel, spacers having an appropriate length and a thickness of 0.5 to 1 mm are arranged with a gap between the spacers (frame material thickness + spacer = regular thickness).
Pressure is applied from above the spacer with the upper surface heating / pressure platen. A method in which the surface material is set between the frame material and the spacer, and the trapped air is released from the gap.

[0006]

In any of the above methods, the thickness of the molded product is thinner than the regular thickness at the frame portion, that is, at the periphery of the sandwich panel, or when the upper surface is added during molding. The air trapped in the temperature / pressure platen and the upper surface material tends to cause dents on the surface of the sandwich panel, and at the same time, the appearance tends to deteriorate. In order to solve the above-mentioned problems, a simple molding method capable of molding a molded product having excellent sandwich panel thickness accuracy is provided.

[0007]

A lower surface material, a rectangular frame material, and an upper surface material are sequentially set on the upper and lower heating / pressing platens in advance and pressurized. A rigid urethane stock solution is injected into a molding space formed by the lower surface material, the rectangular frame material, and the upper surface material, and foamed and cured. At least one surface material is made of a soft material, and a rigid urethane foam is integrally molded. In the molding of the sandwich panel, a frame side having an injection hole in the frame material, and two or more exhaust holes are provided on the frame side opposite to the frame side, and further, in the vicinity of the frame short side of the frame material, Provide exhaust means on the upper surface material,
The gas left between the upper surface material and the heating / pressure platen is
An object of the present invention is to provide a method for molding a heat insulating sandwich panel for building material, wherein the method comprises discharging the gas from the exhaust means through an exhaust hole through a molding space. When the exhaust means provided on the upper surface material is a pinhole row, a plurality of pinholes are arranged near the short side end of the frame material. When the exhaust means is a slit row, a plurality of slits are arranged in parallel with the long side of the frame material and near the short side end of the frame material.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The exhaust means will be described in detail. At least two exhaust holes are provided in the frame material for each short frame. The hole diameter of the exhaust hole is 2 if the frame material thickness is 3 to 5 mm.
The diameter of 5 mm or more is 5 to 8 mm if it is 5 mm or more, and is determined in a known technical range by the reactivity of the hard polyurethane stock solution, the thickness of the frame material, and the like.

The exhaust means and the size thereof are basically selected depending on the size of the sandwich panel. Depending on the panel size, the amount of deflection of the surface material changes, and the amount of air in the local space changes. However, the surface tension and the like of the surface material fluctuate depending on the type of the surface material, the degree of moisture absorption, and the like, and it is necessary to consider the plurality of factors in the evaluation of the ease of bending.

As a rough guide, 1 m ² (1000 × 10
In the case of a size up to about 00, 500 × 2000, etc.), usually, a pinhole exhaust processing means is used, and the larger the number and the larger the number of pinholes, the greater the effect. However, on the other hand, problems such as surface contamination due to liquid leakage, problems due to partial adhesion between the upper surface material and the upper surface heating / pressure platen due to the leaked liquid, or occurrence of additional processing required for pinhole processing, etc. Disadvantages also occur. Further, since the holes are opened even if the liquid does not leak, there arises a problem that urethane is visible when the product is manufactured. The diameter, number, and position of the pinholes correspond to the number of pinholes depending on the shape of the panel and the like so that the air remaining at the beginning does not remain. As a preferred example of the diameter and position, holes of about 1 mmφ are formed at a pitch of about 30 mm within 20 mm from the short frame.

When the panel size is 1 m ² or more, a slit row is preferable. The greater the length and number of slits, the greater the effect, the greater the effect. On the other hand, if the length is too long (30 mm or more), the slits will not fit well when the surface material is pressed by the foam, and the foam will leak, The surface of the material is contaminated, and the long slit is partially closed (non-opening), resulting in an increase in troubles such as an increase in useless man-hours.
As a preferred example, near the edge of the short frame (length, pitch mm)
= (30, 100), (15, 50), (10, 30)
Machining a row of slits.

Next, the function of the exhaust means at the time of forming the heat insulating sandwich panel for building materials will be described. A urethane stock solution mixed by a urethane foaming machine is injected into a molding space from an injection hole provided in the frame material, and foaming, curing, and demolding are performed to integrally mold the sandwich panel. After the injection of the urethane undiluted solution, a stopper such as polyethylene or urethane foam, or an auto stopper made of a resin plate or the like is used to prevent the injected urethane undiluted solution from leaking. As the surface material made of a soft material, paper on which aluminum is deposited or laminated, paper coated with asphalt, paper on which a polyethylene film is laminated, polyethylene film, and the like are usually used. However, it is also possible to use a plywood, a metal plate, a synthetic resin plate or the like having a hard material as the lower surface material. Further, as the rigid urethane foam, an isocyanurate-modified rigid urethane foam is also used.

The air trapped by the soft surface material under its own weight and confined in the local space between the upper surface heating / pressure platen and the surface material is:
As the injected urethane liquid foams, it is extruded around the molded panel as it foams, and finally flows into the panel molding space through the above-mentioned slit row or pinhole row,
Further, the air is discharged to the outside through an exhaust hole provided in the frame material.

The slit array is formed when the foam pushes up the surface material and comes into close contact with the upper surface plate, and the gap becomes extremely small, so that the reaction product does not leak from the slit and contaminate the surface material ( Until then, the slit cuts are open and the air is let through. Also, the pinhole row is open before the surface material is pushed up and the air passes, but when pushed up, the pinhole is covered by the upper surface heating and pressure platen, and the reaction products leak similarly and the surface material is leaked. There is no pollution.

[0015]

1 to 7 show a method of forming a building material panel according to the present invention.
This will be described in detail with reference to FIG.

Forming spaces are formed by setting surface materials on the upper and lower surfaces of the frame 1 respectively. Five pinholes 10 (1 mm diameter) are machined at four corners near the short frame of the upper surface material 2 constituting the molding space at a pitch of 30 mm and a distance of 20 mm from the short frame. (FIGS. 1a, b)

A kraft paper laminated with a polyethylene film as a lower surface material, a frame material made of plywood, and a kraft paper laminated with a polyethylene film as an upper surface material are sequentially set between the upper and lower heating / pressing plates 5 and 6. Then, pressure bonding is performed on the upper and lower heating / pressure platens. The upper surface material 2 is bent by its own weight, and forms a residual space 11 between the upper surface heating and pressurizing platen 5 (FIG. 2). The temperature of the upper and lower surface heating / pressurizing platen is 35 ± 5 ° C. because a general-purpose polyurethane is used as the raw material 7. A raw material liquid injection hole 1 is provided in the short side of the frame material 1.
There are two. A gas exhaust hole 8 having a diameter of 5 mm is formed in the frame material at 5 mm from both ends of the short side frame, that is, a portion intersecting both long sides (FIG. 6).

A hard urethane raw material liquid is injected from a high-pressure urethane foaming machine, and after injection, the injection hole 12 is plugged.

Simultaneously with the pouring, the hard urethane raw material liquid undergoes a foaming / curing process to produce urethane foam. Due to the increase in the volume of the foam, the central portion of the surface material 2 is pressed against the upper surface heating / pressure platen 5 (FIG. 4). While gradually expanding the press-contact area in the plate-shaped molding space 4, the plate-shaped molding space 4 expands and becomes plate-shaped in the surface direction. Forming of the foam proceeds along the long side of the frame 1. As the plate area increases, the residual gas remaining in the molding space 4 moves to the shorter side of the frame 1.
The expanded front end of the plate-shaped body reaches the center of the short side of the frame member 1 and finally reaches the four corners of the rectangular frame to form four final spaces 15 (FIG. 5). This phenomenon, that is, the movement of the foam tip and the expansion of the plate area indicate that the residual gas in the molding space 4 is simultaneously discharged from the exhaust hole.

Before the raw material is supplied, the air left between the surface material 2 and the upper surface heating / pressure platen 5 created by the bending of the surface material 2 under its own weight is transferred to the final space 15 as the foam grows. Between the four corners of the surface material 2 and the upper surface heating / pressure platen 5. At the four corners of the surface material 2, pinhole rows 1 with a diameter of 1 mm
There is 0. The residual air driven into the four corners leaks from the pinhole row 10 into the plate-shaped molding space 4. Due to the growth of the panel plate area at the four corners of the rectangular frame, the residual air leaking into the final space 15, which is the final phase of the plate-shaped molding space 4, is removed from the exhaust holes 8 (FIG. 6).

When the residual air is eliminated, the plate-like panel 13 fills the space between the upper and lower heating / pressing plates 5 and 6 over the entire area of the inner dimensions of the frame 1. Crimp. That is, the thickness of the hard urethane sandwich panel 13 is equal to the interval between the two stools 5 and 6 at all surface positions (FIG. 7).

[0022]

According to the present invention, in forming a sandwich panel for building material using a hard urethane raw material, exhaust holes are provided near both ends of a short side of a rectangular frame material forming a molding space of a molding panel, and an upper surface forming an upper surface of the molding space. By providing a row of slits or a row of pinholes near the four corners of the rectangular frame of the material, any residual gas that adversely affects molding is removed.
By discharging the urethane raw material by the force of foaming and volume expansion, the problem of dent on the surface or the problem of thickness of the molded product was improved.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram of a surface material set on an upper surface of a frame material. b It is an enlarged conceptual diagram of the pinhole row cut in the corner of the surface material.

FIG. 2 is a conceptual cross-sectional view of a molded panel before a hard urethane raw material is supplied, illustrating a deflection of a surface material by its own weight.

FIG. 3 is a conceptual diagram illustrating a position of a perforation of an exhaust hole.

FIG. 4 is a conceptual diagram in a molding space at the beginning of a foaming reaction of a urethane raw material.

FIG. 5 is a conceptual view of a molding space as viewed from the end of a foaming reaction.

FIG. 6 is a conceptual diagram showing an outflow path of a residual gas in the cross section of FIG. 5A and A ′.

FIG. 7 is a conceptual diagram showing a sandwich panel material having a uniform thickness at the end of a foaming reaction.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Frame material 2 Upper surface material 3 Lower surface material 4 Molding space 5 Upper surface heating / pressure platen 6 Lower surface heating / pressure platen 7 Hard urethane raw material 8 Exhaust hole 9 Plug 10 Pinhole row 11 Surface material and upper surface Residual space between heating and pressure platen 12 Raw material injection hole 13 Molded sandwich panel material 14 Foamed foam material 15 Final space

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification number Agency reference number FI Technical indication B29L 31:10 (72) Inventor Mitsuru Akahira 2-1-1 Oshima Koto-ku, Tokyo Tostem shares In company

Claims (3)

[Claims] 1. A bottom surface material, a rectangular frame material, and an upper surface material are sequentially set on a lower surface heating / pressure platen, and pressurized by an upper surface heating / pressure platen to be provided on the frame material. Inject the hard urethane stock solution into the molding space formed by the lower surface material, the rectangular frame material, and the upper surface material from the injection hole, and foam and harden it.
In molding a hard urethane foam integral molded sandwich panel whose surface material is made of a soft material, each of two sides of a frame side having an injection hole in a frame material and a frame side opposite to the frame side are formed.
At least one exhaust hole is provided, and exhaust means is provided on the upper surface material in the vicinity of the frame short side of the frame material, and the upper surface material is heated and
A method for molding a heat-insulating sandwich panel for building material, wherein gas left between the pressurized platens is discharged from the exhaust means through an exhaust hole via a molding space. 2. The heat-insulating sandwich panel for building materials according to claim 1, wherein the exhaust means provided on the upper surface material is a pinhole row and is disposed near a short side end of the frame material. Method. 3. The frame according to claim 1, wherein the exhaust means provided on the upper surface member is a row of slits, and is arranged in parallel with a long side of the frame member and near a short side end of the frame member. A method of molding heat-insulating sandwich panels for building materials.